Mattress Shredding with the Lindner Urraco 75DK

Mattresses are bulky, difficult to handle and can contain a combination of foam, textiles, fibres, plastics and metal springs.

For waste management companies processing large volumes, having the right mattress shredder can make a significant difference to throughput, operating costs and the efficiency of the overall recycling process.

The Lindner Urraco 75DK has demonstrated its ability to handle mattresses at impressive rates.

During an extensive on-site trial with Mach Tech Services, the Urraco 75DK shredded more than 2,500 mattresses across three 9.5-hour shifts, with reported fuel consumption of approximately 29–30 litres per hour.

A separate demonstration at Warren Farm in Hampshire produced another impressive result: 122 mattresses were shredded in just 58 minutes.

That’s approximately:

1 mattress every 28.52 seconds

The results demonstrate the potential of dedicated industrial shredding technology for high-volume mattress processing.

Why Is Mattress Shredding Challenging?

Mattresses are not a straightforward waste stream.

A typical mattress can contain a mixture of:

• Foam
• Textiles
• Fabric
• Fibres
• Plastics
• Metal springs
• Other structural materials

These materials behave differently during processing.

Foam and textiles can be flexible and difficult to grip, while springs and other metal components can place additional demands on the shredding system.

This means that a suitable industrial mattress shredder needs to combine robust cutting technology with sufficient torque and intelligent machine control.

The Lindner Urraco 75DK

The Lindner Urraco 75DK is a mobile twin-shaft shredder designed for demanding waste processing applications.

The machine used during Mach Tech’s demonstrations featured:

• 276 kW of engine power
• Up to 240,000 Nm of torque from the cutting system gearbox
• Scania Tier 4 Final engine
• AdBlue system
• Touchscreen operation
• Remote control
• Eight programmable operating modes

These features allow the Urraco 75DK to be configured for different material types and operating requirements.

For operators processing predominantly mattresses, the ability to configure the machine around the material can be particularly valuable.

2,500+ Mattresses in Three Shifts

One of the most impressive results from the Urraco 75DK mattress shredding trial came during an extensive on-site demonstration.

The machine processed:

2,500+ mattresses

over:

3 × 9.5-hour shifts

with reported fuel consumption of:

29–30 litres per hour

The trial demonstrated that the Urraco 75DK could operate continuously across extended working periods while maintaining the required shredding performance.

For a commercial mattress recycling operation, this type of sustained performance is an important consideration.

122 Mattresses in 58 Minutes

A further demonstration at Warren Farm in Hampshire provided another impressive indication of the Urraco 75DK’s mattress shredding capabilities.

During the trial, the machine processed:

122 mattresses

in:

58 minutes

That’s equivalent to approximately:

126 mattresses per hour

or roughly:

1 mattress every 28.52 seconds

The original Mach Tech case study reports that the machine completed the demonstration without hindrance.

Actual throughput will naturally depend on factors such as mattress size, feed method, material composition and operating configuration, but the demonstration provides a useful real-world indication of what the machine can achieve.

Continuous Mattress Shredding

The Urraco 75DK can be reprogrammed specifically for continuous mattress shredding.

This is particularly useful for waste operators whose business model involves processing large volumes of mattresses rather than periodically processing them alongside other waste streams.

Dedicated programming allows the machine’s operating parameters to be configured around the characteristics of the material.

For a high-volume mattress recycling operation, continuous processing can help improve:

• Throughput
• Machine utilisation
• Operator productivity
• Processing consistency
• Overall site efficiency

A Dedicated Mattress Recycling Application

The Urraco 75DK has also been used by McGrath’s Group, which operates waste management and recycling services in London and the South East.

The company already operated several Lindner stationary shredders, including a Lindner Jupiter primary shredder and Lindner Komet secondary shredder, before purchasing a Urraco.

The Urraco was purchased to process an application consisting of approximately:

90% mattresses

and

10% wood

This is a good example of how a mobile shredder can be configured around a specific waste stream rather than being used as a general-purpose machine.

Why Choose a Mobile Mattress Shredder?

A mobile shredder offers flexibility that can be particularly useful for waste management companies.

Instead of relying solely on a fixed processing line, a mobile machine can be positioned where material needs to be processed.

Potential advantages include:

• Greater site flexibility
• Reduced material movement
• Easier stockpile processing
• Ability to process material at different locations
• High-volume mobile processing
• Flexible application management

For businesses handling mattresses from multiple collection routes or sites, mobility can be a significant advantage.

Fuel Efficiency and Operating Costs

Throughput is only one part of the equation when assessing a mattress shredding machine.

Operators also need to consider the cost of running the equipment.

Important factors include:

• Fuel consumption
• Wear-part life
• Maintenance
• Downtime
• Operator requirements
• Throughput
• Output quality

During the Mach Tech trial, the Urraco 75DK recorded fuel consumption of approximately 29–30 litres per hour while processing mattresses.

The machine’s Scania Tier 4 Final engine and AdBlue system are designed to provide efficient operation while meeting applicable emissions requirements for the engine configuration.

High Torque for Difficult Materials

Mattresses may look relatively lightweight compared with other waste streams, but the combination of bulky material, textiles, foam and metal components can make them demanding to process.

The Urraco 75DK’s cutting system gearbox produces up to 240,000 Nm of torque, providing the power required for demanding shredding applications.

High torque helps the twin-shaft cutting system maintain force when material enters the shredding chamber.

This is particularly useful where the feedstock contains resilient or difficult-to-process materials.

Simple Machine Operation

High-performance machinery doesn’t need to be complicated to operate.

The Urraco 75DK features:

• Touchscreen control
• Remote control
• Programmable operating modes

The machine has eight programs for different material types, allowing the operator to select an appropriate operating configuration for the application.

For a business processing predominantly mattresses, this provides the opportunity to establish a repeatable operating profile specifically for that waste stream.

From Mattress Waste to Recovered Materials

Shredding is an important stage in the mattress recycling process.

Once mattresses have been reduced in size, the resulting material can be processed through downstream separation systems.

Depending on the facility and mattress composition, potential recoverable materials can include:

• Ferrous metals
• Foam
• Textiles
• Fibres
• Plastics

The exact recovery process depends on the composition of the mattresses and the downstream equipment installed at the recycling facility.

A good mattress shredder therefore needs to produce an output suitable for whatever separation or recovery process follows.

Why Mattress Recycling Requires the Right Equipment

A high-volume mattress recycling operation can quickly accumulate large quantities of bulky waste.

Without suitable processing equipment, mattresses can:

• Take up significant storage space
• Be difficult to transport efficiently
• Require considerable manual handling
• Slow down waste processing operations

Shredding reduces the volume and size of the material, making subsequent handling and processing more manageable.

For operators handling thousands of mattresses, investing in suitable mattress recycling equipment can therefore have a significant impact on site efficiency.

Choosing a Mattress Shredder

When selecting a mattress shredder, there are several factors to consider.

1. Throughput

How many mattresses need to be processed per hour or day?

2. Material Composition

What percentage of the feedstock is foam, textile, metal or other material?

3. Output Size

What particle size is required for the next stage of processing?

4. Operating Hours

Will the machine run intermittently or continuously?

5. Mobility

Does the shredder need to move around the site?

6. Fuel Consumption

What is the expected fuel requirement at the desired throughput?

7. Wear

How frequently will cutting components need inspection or replacement?

8. Downstream Processing

What separation and recycling equipment will receive the shredded material?

Considering all of these factors helps ensure that the machine is matched to the application.

Lindner Urraco 75DK: Built for Demanding Applications

The Urraco 75DK provides a combination of power, torque, mobility and programmable operation.

The Mach Tech mattress trials demonstrate its ability to operate at high rates on a demanding waste stream.

From more than 2,500 mattresses processed across three extended shifts to 122 mattresses in 58 minutes, the machine has demonstrated strong real-world performance in mattress shredding applications.

For businesses looking to increase the efficiency of their mattress recycling operation, the Urraco 75DK is a compelling option to consider.

Mach Tech Services, Mattress Shredding Solutions

Mach Tech Services is the sole distributor of Lindner Recyclingtech shredders in the UK and Ireland.

We supply and support shredding technology for a wide range of applications, including:

• Mattress recycling
• Waste wood recycling
• Plastics recycling
• Metal recycling
• SRF production
• RDF production
• Bulky waste
• Commercial and industrial waste

Our support includes:

• Application consultation
• Machine supply
• Installation
• Commissioning
• Preventative maintenance
• Breakdown repairs
• Genuine spare and wear parts
• Precision engineering
• Welding
• Hardfacing
• Full shredder rebuilds

With over £1 million worth of spare and wear parts held in stock, Mach Tech can also help customers keep their shredding equipment operating efficiently.

Looking for a Mattress Shredder?

If your business processes large volumes of mattresses, selecting the right industrial mattress shredder can make a significant difference to throughput, operating costs and overall productivity.

The Lindner Urraco 75DK has demonstrated its ability to process mattresses continuously, including more than 2,500 mattresses over three extended shifts and 122 mattresses in 58 minutes during separate Mach Tech demonstrations.

Mach Tech Services can assess your material, throughput requirements and processing objectives to help identify the right Lindner shredding solution.

Call Mach Tech Services on 01706 838 246 to discuss your mattress shredding requirements.

Frequently Asked Questions

What is a mattress shredder?

A mattress shredder is an industrial machine designed to reduce discarded mattresses into smaller pieces for easier handling, transport and downstream recycling or recovery.

Can the Lindner Urraco 75DK shred mattresses?

Yes. The Urraco 75DK has been specifically demonstrated processing large volumes of mattresses, including a trial where more than 2,500 mattresses were shredded across three 9.5-hour shifts.

How many mattresses can a Urraco 75DK shred per hour?

During a Mach Tech demonstration at Warren Farm, the Urraco 75DK processed 122 mattresses in 58 minutes, equivalent to approximately 126 mattresses per hour. Actual throughput will vary depending on material and operating conditions.

How quickly can the Urraco 75DK shred a mattress?

During the Warren Farm demonstration, the average processing rate was approximately one mattress every 28.52 seconds.

Can the Urraco 75DK continuously shred mattresses?

Yes. The Urraco 75DK can be programmed specifically for continuous mattress shredding, making it suitable for dedicated high-volume mattress processing applications.

What is the fuel consumption of the Urraco 75DK when shredding mattresses?

During the Mach Tech trial, the machine recorded fuel consumption of approximately 29–30 litres per hour while processing mattresses.

What power does the Urraco 75DK have?

The Urraco 75DK featured 276 kW of engine power in the configuration described in the original Mach Tech case study. Its cutting system gearbox produces up to 240,000 Nm of torque.

Can mattresses be recycled after shredding?

Yes. Depending on the mattress and recycling process, materials such as metal, foam, textiles and fibres can potentially be recovered following shredding and separation.

Is the Urraco 75DK mobile?

Yes. The Urraco 75DK is a mobile twin-shaft shredder, providing flexibility for waste operators that need to process material at different locations.

Can the Urraco shred materials other than mattresses?

Yes. The machine is designed for a range of demanding waste processing applications. The McGrath application described in the original article involved approximately 90% mattresses and 10% wood.

Can Mach Tech supply a mattress shredder in the UK?

Yes. Mach Tech Services is the sole distributor of Lindner Recyclingtech shredders in the UK and Ireland and can help businesses assess their mattress recycling and shredding requirements.